PC-based Control:
Cut Costs Using Comprehensive
Energy Data Management.
IPC
I/O
Automation
We reserve the right to make technical changes.
BECKHOFF New Automation Technology
2
Energy and raw materials:
discover your
savings potential.
Cost pressures and efficiency optimisation: all
manufacturing enterprises face these challenges
every day. The PC-based control system from
Beckhoff maximises savings potential in key
areas, ensuring that these challenges are solved.
The first covers raw materials savings through
fast, high-precision control technology in the form
of eXtreme Fast Control technology (XFC) –
explained in detail at www.beckhoff.com/XFC.
2
BECKHOFF New Automation Technology
We reserve the right to make technical changes.
Company
If you want to meaningfully lower the costs of
energy, you have to look at the big picture: and
create transparency with regard to consumption
by offices, conference rooms, cafeterias, foyers,
administration wings, basements and auxiliary
buildings.
Production
If you want to lower the costs associated with
energy and raw materials, you have to do so
in all production areas at the same time: that
begins with the determination of the peak
load and usage of all production plants.
Machines
and plants
If you want to lower the costs of energy and
raw materials, you have to consciously think
small: and measure the consumption of even
the smallest actuator with the utmost precision.
The second key savings factor: robust energy
management that covers the full spectrum of
buildings, production facilities and machines with
one universal platform. Massive cost savings are
possible here – on one condition: complete, transparent acquisition and processing of all energy
consumption data from the whole enterprise.
This ensures that the best energy management
decisions can be made to best drive down costs.
Beckhoff establishes this transparency for energy
We reserve the right to make technical changes.
data management technology that can be directly
integrated into your PC-based automation controller. This way, machines can be analysed and classified in the simplest possible way, “energy hogs”
can be dealt with and all relevant key metrics can
be determined. As a result, your facility can also
become a “Smart Factory” in terms of energy
efficiency – while at the same time fulfilling
demanding energy requirements and regulations
from around the world, such as ISO 50001.
Intelligent energy management
significantly optimises efficiency.
Beckhoff supports the transparent
acquisition and processing of all energy
consumption data.
Direct integration in a standard PC-based
controller
Fulfils energy efficiency requirements
such as ISO 50001
BECKHOFF New Automation Technology
3
Universal and fully transparent:
monitoring, measurement and
analysis with PC-based control.
Production
Administration
Logistics
Production 2
Production n
Ethernet, OPC UA, IoT Communication
Production 1
Ethernet, OPC UA, IoT Communication, Database Server
Machine 1
Sensor/Actuator
Machine 2
Sensor/Actuator
Machine n
Sensor/Actuator
EtherCAT, EAP, OPC UA, IoT Communication, ADS, Database Server
4
BECKHOFF New Automation Technology
We reserve the right to make technical changes.
Energy Management System
OPC UA
Company
Database
Current
Heat | Gas
The consumption of electricity, heat, water and
gas is monitored at all company levels, analysed
and then supplied to the higher level energy
management system via OPC-UA.
Water
Wearable
Device
Database
Production
Current
Heat | Gas
From the small business to the global enterprise
with multi-site operations: Beckhoff monitors the
energy consumption, detects air pressure leaks
in the field, for example, and visually displays all
production-related energy data.
Wasser
Air pressure consumption
Visualisation of the
production data
Database
Machines and plants
Current
Air pressure consumption
Electricity, air pressure consumption, temperature
and machine-specific data are monitored and
recorded directly on-site in the field.
Temperature
Condition Monitoring
Beckhoff creates the foundation for highly efficient
energy data management with PC-based control
technology. It is essential to look at the picture as a
whole: the measurement of all energy consumption
in the enterprise is just as important as the highprecision acquisition of the data for each individual
consumer. Therefore, Beckhoff offers the power to
measure energy consumption precisely, right where
it takes place – at any location within the company
in each area, at each machine and directly at each
We reserve the right to make technical changes.
actuator. The energy consumption is measured via
distributed I/O systems from Beckhoff. The raw data
are transmitted to the controller via the fast, broadband EtherCAT system. TwinCAT control software
enables pre-processing of data, such as analyses,
scope and HMI functions. All energy data are supplied
to the higher-level energy management system via
standardised interfaces such as OPC-UA.
High-precision measurement of total
resource consumption and of each
individual consumer
Energy consumption recording via
Beckhoff I/O
Data transmission via EtherCAT
industrial Ethernet system
Data pre-processing via TwinCAT software
Transfer to higher level energy
management systems via OPC-UA
BECKHOFF New Automation Technology
5
System-integrated
energy data management:
the simple extension to your
PC-based controller.
Through a wide range of I/O Terminals with advanced
functionality, Beckhoff integrates measurement
technology directly into the standard I/O system.
Modular measuring terminals are available for
applications that range from the measurement
of temperature, power, current and voltage up to
complex mains monitoring or Condition Monitoring.
The signals are made available to the controller as
raw data for processing. Now only one controller is
required for automation and energy data management
– TwinCAT automation software covers everything
in one universal system: System Manager, engineering,
runtime functions such as PLC, motion control and
measurement modules such as condition monitoring
Direct measurement
EL3403 and KL3403 3-phase power
measurement, 500 V AC
EL3413 3-phase power measurement,
690 V AC
EL3773 high-end power analysis
Indirect measurement (meter)
KL6401 LON Bus Terminal
KL6781 M-Bus master terminal
EL6224, KL6224 IO-Link master terminals
EL1xxx/KL1xxx digital input terminals
(acquisition of pulse outputs)
Current
Heat | Gas
6
BECKHOFF New Automation Technology
or scope. PC-based control significantly simplifies
implementation and retrofitting requires little effort.
At the same time, the Beckhoff principle of open
control technology and the high signal variety in
the I/O system guarantee maximum flexibility and
compatibility with existing equipment and facilities.
Indirect measurement (meter)
KL6401 LON Bus Terminal
KL6781 M-Bus master terminal
Water
We reserve the right to make technical changes.
Big Data
Energy Management System
TC Database Server, OPC UA
Database
Industrial PC
Connectivity
TF6100 | TC3 OPC UA
TF6420 | TC3 Database Server
TF6421 | TC3 XML Server
TF6500 | TC3 IEC 60870-5-10x
TF670x | TC3 IoT Communication
Measurement technology
TF3600 | TC3 Condition Monitoring
TE1300 | TC3 Scope View
Direct measurement
EP3744 pressure measurement box
KM37xx and EM37xx pressure measurement
terminals
Direct measurement
KL33xx, EL33xx and EP3314 thermocouple
KL32xx, EL32xx and EP3204 resistance
sensor RTD
Direct measurement
EL3632 CMS terminal (IEPE)
Indirect measurement (analog)
EL3xxx and KL3xxx analog input terminals
EP3xxx analog input modules
EL6224, KL6224 IO-Link master terminals
Air pressure consumption
We reserve the right to make technical changes.
Temperature
Condition Monitoring
BECKHOFF New Automation Technology
7
Solutions that
maximise your
energy cost savings.
8
BECKHOFF New Automation Technology
We reserve the right to make technical changes.
Administration
Ethernet
KL6781
KL3403
Energy data management in
building automation:
Embedded PC with TwinCAT 3
Bus Terminals
– current: KL3403 3-phase power
measurement terminal
– water: KL6781 M-Bus master terminal
3 x 230 V AC
Current
Water
meter
Production
Current converter
Lighting
Ethernet
Energy data management in production facilities:
Industrial PC with TwinCAT 3
Bus Terminals
– gas: EL1004 digital input terminal
– air pressure consumption: EL6224 IO-Link
master terminal
EL1004
EL6224
Flow
sensor
Gas meter
Ethernet
Machines and plants
Energy data management on the machine:
Industrial PC with TwinCAT 3
EtherCAT Terminals
– EL3403 3-phase power measurement terminal
– EL3632 condition monitoring terminal
EL3632
EL3403
Current
Current
converter
IEPE
sensor
We reserve the right to make technical changes.
BECKHOFF New Automation Technology
9
Integrated energy data management enables
the implementation of ISO 50001…
Continuous
improvement
Energy policy
Management
review
Energy planning
Introduction and
implementation
Monitoring,
measurement
and analysis
Control
Internal auditing of
the EnMS
Nonconformity, correction,
corrective and preventive
actions
Source: ISO 50001
An initial implementation as well as the constant,
optimised compliance with ISO 50001 or certification according to EMAS (Eco-Management and
Audit Schemes) is compulsory for tax breaks and
refunds related to energy and environmental taxes
in many countries. Continuous, highly precise
energy data are required for these improvements.
Beyond that, the Energy Efficiency Directive (EED)
requires that all companies not falling under the
definition of “small enterprises” implement an
10
BECKHOFF New Automation Technology
energy audit as well as an energy or environmental
management system. In this context, Beckhoff
supplies the ideal automation toolkit to successfully
implement reliable and continuous monitoring,
analysis and evaluation of data around the world.
Continuous energy management
optimisation reduces tax burdens
Potential for energy tax breaks and
refunds
Potential for environmental tax breaks
and refunds
We reserve the right to make technical changes.
… creating the basis for extensive
and actionable analyses.
Power/kWh
50
Load curve determination
with PC-based control.
45
40
Peak Load
35
PC-based control supplies the data on the basis
of which load curves are created, the peak loads
are determined and peak load compensation is
enabled.
30
25
20
15
10
5
Mid Load
Basic Load
0
00:00
7:30
23:45
t
Power/kWh
25
Operation during analysis
with PC-based control.
20
PC-based control supplies data on the basis of
how to best determine the percentage of total load
attributable to each individual load as well as the
basic and mean loads.
Peak Load
15
10
5
Mid Load
Basic Load
0
0%
10 %
20 %
Energy consumption
30 %
40 %
50 %
60 %
70 %
80 %
90 %
Total execution time
Connected load [kW]
10
Portfolio comparison
with PC-based control.
8
6
PC-based control can also help illustrate and compare the energy consumption data of individual
machines in relation to other machines.
4
2
0
0
2
4
6
8
10
Operating time [h/day]
An energy data management system from Beckhoff
enables you to achieve transparency regarding
energy consumption in your enterprise and helps
tailor your energy management precisely to your real
world consumption characteristics. With the data
provided by the Beckhoff system you can precisely
determine peak loads and carry out peak load
compensation. The percentage of the total load
attributable to each individual load can be determined with great precision, and using the portfolio
We reserve the right to make technical changes.
comparison you can identify the “energy hogs”
in your production and initiate the appropriate
measures via comprehensive energy management.
All analyses take place with the help of the data
provided from the automation controller: It could
hardly be any simpler or more integrated.
PC Control supplies all data for energy
consumption analysis
Precise peak load determinations
Operating duration analyses
Portfolio comparisons
BECKHOFF New Automation Technology
11
DK3682-1115
Transparent energy data management:
With PC-based Control.
For further information see
www.beckhoff.com/energy-data-management
Beckhoff Automation GmbH & Co. KG
Huelshorstweg 20
33415 Verl
Germany
Phone: + 49 5246 963-0
[email protected]
www.beckhoff.com
Beckhoff®, TwinCAT®, EtherCAT®, Safety over EtherCAT®, TwinSAFE®, XFC® and XTS® are registered trademarks of and licensed by Beckhoff Automation GmbH.
Other designations used in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owners.
© Beckhoff Automation GmbH & Co. KG 11/2015
The information provided in this brochure contains merely general descriptions or characteristics of performance which in case of actual application do not
always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall
only exist if expressively agreed in the terms of contract.
1
BECKHOFF New Automation Technology
Picture credits:
GettyImages - Yoshinori Kuwahara (page 1-2)
Koch (page 8)
Miele (page 8)
nobilia Werke J. Stickling GmbH & Co. KG
(page 8)
We reserve the right to make technical changes.